Image processing apparatus

ABSTRACT

Plural items of two-dimensional image processing and at least one item of a three-dimensional measurement process are registered in a processing item table. The items of two-dimensional image processing include at least one item of an on-first-image position specification process of specifying a position on a physical object in a first image. A sequence building unit combines the item of the on-first-image position specification process and the item of the three-dimensional measurement process to set the sequence for three-dimensional measurement by selection of a user.

This application claims priority from Japanese patent applications JPP2005-178540, filed on June 17, 2005 and JP P2005-178546, filed on Jun.17, 2005. The entire contents of the aforementioned applications areincorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an apparatus which performs athree-dimensional measurement based on images taken by plural cameraswhich are arranged so as to take a physical object from differentdirections.

2. Description of the Related Art

Conventionally, an apparatus which perform a measurement to a shape anda surface pattern of the physical object by two-dimensional imageprocessing is widely used on various production sites. In this kind oftwo-dimensional image processing apparatus, the measurement is performedbased on the image in which a representative surface (for example, abottom surface of the physical object) of the physical object or ameasurement target surface (including an inspection target surface) ofthe physical object is taken from a direction perpendicular to thesurface, i.e., the direction in which the surface is viewed from a frontside. In this case, the term “measurement” shall include a measurementfor the purpose of inspection. In the following description, the termsimply referred to as “measurement” shall include “measurement for thepurpose of inspection” based on the fact that some sort of measurementis performed in an inspection process.

In order that the same apparatus can be applied to the variousmeasurement purposes, almost all the pieces of two-dimensional imageprocessing apparatus have menus of various processing items, and a usercan build the sequence of the processing items by specifying theprocessing items to be used and an executing procedure. For example,FIG. 9 of Japanese Patent Application Laid-Open No. 2005-167678 shows animage processing apparatus, in which the available processing items arepresented to a user to cause the user to specify the procedure ofexecuting the processing item.

On the other hand, there is a well-known three-dimensional measurementtechnique based on a stereoscopic view principle with plural cameras.For example, Japanese Patent Application Laid-Open No. 2002-99902discloses the three-dimensional measurement technique. However, in thecurrent apparatus for the three-dimensional measurement, a kind and acharacteristic of the physical object are restricted, and a measurementalgorithm is included in order to utilize the given feature of thephysical object to perform the measurement. Therefore, the apparatus isput into practical use as the apparatus dedicated to the physicalobject. For example, Japanese Patent Application Laid-Open No.2002-99902 discloses an image processing apparatus which performs thethree-dimensional measurement to the physical object having arotationally symmetric shape.

If a three-dimensional measurement of a physical object is available onvarious production sites, a measurement which cannot be performed in aconventional two-dimensional image processing apparatus may be realized,and measurement accuracy and usability may be improved than ever before.However, currently there has been no known three-dimensional measurementapparatus which can be widely used on the various production sites.

The inventors do not develop the conventionally general image processingapparatus specializing in the three-dimensional measurement, but developthe apparatus in which the three-dimensional measurement function isadded while the functions of the conventional two-dimensional imageprocessing apparatus are inherited, and thereby the inventors intend tocreate the new type of image processing apparatus having highversatility in which the three-dimensional measurement can be performed.In view of the foregoing, a problem of the invention is to be able tospecify the sequence of the three-dimensional measurement by a userinterface in which the available processing items are presented to causea user to produce the sequence of the processing items, like theconventional two-dimensional image processing apparatus.

Another problem of the invention is to utilize a part of the processused in the conventional two-dimensional image processing apparatus forthe three-dimensional measurement.

SUMMARY OF THE INVENTION

(1) An image processing apparatus of the invention which performs aprocess with a first image and a second image taken by a first cameraand a second camera respectively, the first camera and the second camerabeing arranged so as to take a physical object from differentdirections, the image processing apparatus including sequence settingmeans for setting a sequence of a processing item; and sequenceexecuting means for executing the set sequence, wherein the sequencesetting means provides plural items of two-dimensional image processingand at least one item of a three-dimensional measurement process as theprocessing item which can be set at a sequence element by selection of auser, the provided items of the two-dimensional image processing includeat least one item of an on-first-image position specification process ofspecifying a position on a physical object in the first image, and thethree-dimensional measurement process includes an on-second-imageposition specification process of specifying a position on a physicalobject in the second image, the position on the physical object in thesecond image corresponding to the position on the physical object in thefirst image which is specified in the on-first-image positionspecification process belonging to the same sequence as the sequence towhich the on-second-image position specification process belongs to.

In the image processing apparatus of the invention, the process ofspecifying the position on the first image for the three-dimensionalmeasurement is adopted to be selected from the plural items of thetwo-dimensional image processing. Therefore, the image processingapparatus is highly compatible with the conventional two-dimensionalimage processing apparatus while the three-dimensional measurement canbe performed, and a little amount of teaching is required when a useruses the image processing apparatus. Accordingly, the user can easilyuse the image processing apparatus.

At least three cameras may be used. In this case, the two cameras of atleast the three cameras are set at the first camera and the secondcamera. The images themselves taken by the first camera and the secondcamera may be used as the first image and the second image, or theimages to which some sort of process is performed may be used as thefirst image and the second image. For example, the image in which anoblique image taken by the second camera is converted into the frontimage may be used as the second image. The on-first-image positionspecification process, according to the specifications thereof, can be ageneral-purpose process (program) which can process the second imagedepending on settings.

(2) Further, in the image processing apparatus of the invention, thethree-dimensional measurement process further may include a process ofcomputing a three-dimensional coordinate using the position specified inthe on-first-image position specification process and the positionspecified in the on-second-image position specification process. In thiscase, the process of specifying the position on the second image and theprocess of computing the three-dimensional coordinate are unified in oneprocessing item. Therefore, a user can complete the entire sequence ofthe three-dimensional measurement with the small number of commands, sothat the user can further easily use the image processing apparatus.

(3) Further, in the image processing apparatus of the invention, pluralkinds of items of the on-first-image position specification process andplural kinds of items of the three-dimensional measurement process maybe provided so as to be able to be set at the sequence element by theselection of a user. The above configuration enables the processcontents to be selected in the three-dimensional measurement.Furthermore, the three-dimensional measurement sequences having thenumber of kinds larger than the number of options of the item in itselfcan be produced by combining the items, in the case of the pluralthree-dimensional measurement process items which can be coupled withone on-first-image position specification process item by the selection,or in the case of the plural on-first-image position specificationprocess items which can be coupled with one three-dimensionalmeasurement process item by the selection.

(4) Further, in the image processing apparatus of the invention, in theimage processing apparatus of the invention, a three-dimensionalmeasurement basic sequence may be provided so as to be able to beutilized by the selection of a user, the three-dimensional measurementbasic sequence including at least one item of the on-first-imageposition specification process and at least one item of thethree-dimensional measurement process. According to the aboveconfiguration, a user who is unused to the three-dimensional measurementsequence can further easily utilize the three-dimensional measurementfunction of the image processing apparatus.

(5) Further, in the image processing apparatus of the invention, a firstdetection area may be set to the first image to detect an edge positionin an edge detection direction, the edge position being determined forthe first detection area, in at least one on-first-image positionspecification process to which the processing item is provided, and asecond detection area may be set to the second image, a particularlydirection being set at the edge detection direction in the seconddetection area, the particular direction being determined based on apositional relationship between the first camera and the second cameraand the edge position specified in the on-first-image positionspecification process, in the on-second-image position specificationprocess in at least one three-dimensional measurement process to whichthe processing item is provided. According to the above configuration,the edge position of the physical object can be measured in thethree-dimensional manner.

(6) Further, in the image processing apparatus of the invention, in thesecond detection area, a range along the edge detection direction may beset based on a range along an optical axis of the first camera which isspecified by a user as a three-dimensional measurement target range.Therefore, because the second detection area can be set in the limitedrange corresponding to the range which a user assumes the existence ofthe edge of the measurement target, a computation amount can bedecreased in the on-second-image position specification process, and thenumber of malfunctions can be decreased. The generation of themalfunction is attributed to the fact that the edge which is not themeasurement target is included in the second detection area.

(7) Further, in the image processing apparatus of the invention, thefirst camera may have a rectangular visual field range while arranged soas to take the physical object from a front side, the second camera maybe located at a position which is separated from the visual field of thefirst camera in a longitudinal direction or in a crosswise direction,the second camera may be arranged so as to take the physical object froman oblique direction with respect to the direction in which the physicalobject is seen from the front side, on-first-image positionspecification means may set the first detection area at a position inthe first image based on a user command, and the edge detectiondirection of the first detection area may be located in a row of thefirst camera and the second camera.

Therefore, the edge detection direction is located in the row of thecameras in the process of specifying the edge position when the firstimage is set at the process target, and the longitudinal direction orthe crosswise direction of the visual field of the camera becomes theedge detection direction because the second camera is arranged in thelongitudinal direction or in the crosswise direction of the visual fieldof the first camera. The first image is an image in which the physicalobject is taken from the direction of the front side. The detection areain the first image is set at the position based on the user command, thesetting target image is the front image, and the longitudinal directionor the crosswise direction of the visual field of the camera becomes theedge detection direction. Despite the setting for the three-dimensionalmeasurement, the edge detection area can be set as easy as theconventional two-dimensional image processing apparatus. Accordingly, auser can easily use the image processing apparatus.

(8) Further, in the image processing apparatus of the invention, arepresentative position of an area on the first image having a highdegree of correspondence to a model image may be specified in at leastone on-first-image position specification process to which theprocessing item is provided, the model image being previously registeredbefore the measurement is performed, and a representative position of anarea on the second image having a high degree of correspondence to themodel image may be specified in the on-second-image positionspecification process in at least one three-dimensional measurementprocess to which the processing item is provided. According to the aboveconfiguration, the representative position of the area on the physicalobject having the high degree of correspondence to the previouslyregistered model can be measured in the three-dimensional manner.

(9) Further, in the image processing apparatus of the invention, in theon-second-image position specification process, a search area may be seton the second image based on the positional relationship between thefirst camera and the second camera and the representative positionsspecified in the on-first-image position specification process, and therepresentative position of the area having the high degree ofcorrespondence to the model image may be specified in the search area.Therefore, because the search area can be restricted in the range wherethe measurement target area exists possibly in the second image, acomputation amount can be decreased in the on-second-image positionspecification process, and the number of malfunctions can be decreased.The generation of the malfunction is attributed to the fact that thearea on the second image which is not the measurement target correspondsto the model image.

(10) Further, in the image processing apparatus of the invention, thesearch area may be set based on the range along the optical axis of thefirst camera specified by a user as the three-dimensional measurementtarget range. Therefore, because the search area can be set in thelimited range corresponding to the range which a user assumes theexistence of the measurement target area, the computation amount can bedecreased in the on-second-image position specification process, and thenumber of malfunctions can be decreased. The generation of themalfunction is attributed to the fact that the area on the second imagewhich is not the measurement target corresponds to the model.

(11) Further, in the image processing apparatus of the invention, arepresentative position of a measurement target area set on the firstimage based on the user command may be specified to obtain the image inthe measurement target area as the model image in at least oneon-first-image position specification process to which the processingitem is provided, and a representative position of an area on the secondimage having a high degree of correspondence to the model image may bespecified in the on-second-image position specification process in atleast one three-dimensional measurement process to which the processingitem is provided.

According to the above configuration, the representative position of thearea on the physical object having the high degree of correspondence tothe model obtained from the first image can be measured in thethree-dimensional manner. Because the model is actually obtained fromthe image which is of the target of the measurement process, thethree-dimensional measurement can be performed even if the characters orpatterns on the surface which is of the measurement target is changed ineach physical object. When the plural areas in the physical object areindividually measured, the three-dimensional shape (a three-dimensionalcoordinate distribution of the physical object surface) can also beobtained.

(12) Further, in the image processing apparatus of the invention, in theon-second-image position specification process, a search area may be seton the second image based on the positional relationship between thefirst camera and the second camera and the representative positionsspecified in the on-first-image position specification process, and therepresentative position of the area having the high degree ofcorrespondence to the model image may be specified in the search area.Therefore, because the search area can be restricted in the range wherethe measurement target area exists possibly in the second image, thecomputation amount can be decreased in the on-second-image positionspecification process, and the number of malfunctions can be decreased.The generation of the malfunction is attributed to the fact that thearea on the second image which is not the measurement target correspondsto the model image.

(13) Further, in the image processing apparatus of the invention, thesearch area is set based on the range along the optical axis of thefirst camera specified by a user as the three-dimensional measurementtarget range. Therefore, because the search area can be set in thelimited range corresponding to the range which a user assumes theexistence of the measurement target area, the computation amount can bedecreased in the on-second-image position specification process, and thenumber of malfunctions can be decreased. The generation of themalfunction is attributed to the fact that the area on the second imagewhich is not the measurement target corresponds to the model.

(14) The solving means realized by the image processing apparatus of theinvention can also be comprehended as an image processing method. Animage processing method of the invention in which a first image and asecond image respectively taken by a first camera and a second cameraare used, the first camera and the second camera being arranged so as totake a physical object from different directions, the image processingmethod including a sequence setting step of setting a sequence of aprocessing item; and a sequence executing step of executing the setsequence, wherein the sequence setting step provides plural items oftwo-dimensional image processing and at least one item of athree-dimensional measurement process as the processing item which canbe set at a sequence element by selection of a user, the provided itemsof the two-dimensional image processing include at least one item of anon-first-image position specification process of specifying a positionon a physical object in the first image, and the three-dimensionalmeasurement process includes an on-second-image position specificationprocess of specifying a position on a physical object in the secondimage, the position on the physical object in the second imagecorresponding to the position on the physical object in the first imagewhich is specified in the on-first-image position specification processbelonging to the same sequence as the sequence to which theon-second-image position specification process belongs to.

(15) Further, in the image processing method, the three-dimensionalmeasurement process further may include a process of computing athree-dimensional coordinate using the position specified in theon-first-image position specification process and the position specifiedin the second on-image position specification process.

(16) An image processing apparatus of the invention which performs aprocess with a first image and a second image taken by a first cameraand a second camera respectively, the first camera having a rectangularvisual field range while arranged so as to take a physical object from afront side, the second camera being located at a position which isseparated from the visual field of the first camera in a longitudinaldirection or in a crosswise direction, the second camera being arrangedso as to take the physical object from an oblique direction with respectto the direction in which the physical object is seen from the frontside, the image processing apparatus including on-first-image positionspecification means for specifying a position on the physical object inthe first image; on-second-image position specification means forspecifying a position on the physical object in the second image, theposition on the physical object in the second image corresponding to theposition on the physical object in the first image specified by theon-first-image position specification means; and three-dimensionalcoordinate computation means for computing a three-dimensionalcoordinate using the position specified by the on-first-image positionspecification means and the position specified by the on-second-imageposition specification means, wherein the on-first-image positionspecification means sets a first detection area at a position in thefirst image based on a user command, the on-first-image positionspecification means specifies an edge position in an edge detectiondirection determined for the first detection area, and the edgedetection direction of the first detection area is located in a row ofthe first camera and the second camera, and the on-second-image positionspecification means sets a second detection area to the second image, aparticular direction is set at the edge detection direction in thesecond detection area, the particular direction being determined basedon a positional relationship between the first camera and the secondcamera and the edge position specified in the on-first-image positionspecification means, and the on-second-image position specificationmeans specifies the edge position in the edge detection direction in thesecond detection area.

According to the image processing apparatus of the invention, theprocess of specifying the edge position in the detection area which isused in the conventional two-dimensional image processing apparatus canbe utilized for the three-dimensional measurement by specifying the edgedetection directions for the first image and second image in theabove-described manner. Particularly, the edge detection directionbecomes the direction in the row of the cameras during the process ofspecifying the edge position in the case of the target of the firstimage, and the longitudinal direction or crosswise direction of thevisual field of the camera becomes the edge detection direction becausethe second camera is arranged in the longitudinal direction or crosswisedirection of the visual field of the first camera. The first image is animage in which the physical object is taken from the direction of thefront side. The detection area in the first image is set at the positionbased on the user command, the setting target image is the front image,and the longitudinal direction or the crosswise direction of the visualfield of the camera becomes the edge detection direction. Despite thesetting for the three-dimensional measurement, the edge detection areacan be set as easy as the conventional two-dimensional image processingapparatus. Accordingly, a user can easily use the image processingapparatus.

(17) The solving means realized by the image processing apparatus of theinvention can also be comprehended as an image processing method inwhich contents executed by each process means are set at process steps.

As described above, according to the invention, a user can easily usethe three-dimensional measurement function because the three-dimensionalmeasurement is performed by the apparatus or method which is highlycompatible with the conventional two-dimensional image processing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a configuration of an imaging unit ofan inspection apparatus to which the invention is applied along with aninstallation example;

FIG. 2 shows an explanatory view of examples of images generated bycameras;

FIG. 3 shows a block diagram of the inspection apparatus;

FIG. 4 shows a functional block diagram of a system configuration forsetting a sequence;

FIG. 5 shows an explanatory view of a data configuration example of aprocessing item table;

FIG. 6 shows an explanatory view of a menu display example of asequence;

FIGS. 7A and 7B show explanatory views of a sequence of “edge position”and a flowchart thereof while the sequence is caused to respond to theflowchart;

FIGS. 8A and 8B show explanatory views of a sequence of “pattern” and aflowchart thereof while the sequence is caused to respond to theflowchart;

FIGS. 9A, 9B, 9C, 9D and 9E show explanatory views of an operationalprocedure when another processing item is added to a basic sequence of“edge position”;

FIG. 10 shows an explanatory view of an example in which a processingitem concerning a two-dimensional measurement is added to the basicsequence;

FIG. 11 shows a block diagram of an inspection apparatus;

FIG. 12 shows a flowchart of a procedure concerning IC inspection;

FIG. 13 shows an explanatory view of a setting example of a detectionarea;

FIG. 14 shows a flowchart of a procedure of a teaching process;

FIG. 15 shows an explanatory view of a setting example of a positioningarea;

FIG. 16 shows a flowchart of a detailed procedure of lead inspection;

FIG. 17 shows an explanatory view of a relationship between thepositioning area and the detection area for the work in a front imageduring inspection;

FIG. 18 shows an explanatory view of a relationship of correspondingpoint between images;

FIG. 19 shows an explanatory view of a method of setting the detectionarea;

FIGS. 20A and 20B show explanatory views of a relationship between aheight range and the detection area;

FIG. 21 shows an explanatory view of an example in which an inspectiontarget region on an acceptable work is registered as a model;

FIG. 22 shows a flowchart of a procedure of inspecting a character key;

FIG. 23 shows an explanatory view of an example in which a measurementtarget area and a search area are set for an inspection target image;

FIG. 24 shows an explanatory view of a front image and an oblique imageof a work having a round display area;

FIG. 25 shows an explanatory view of result in which the measurementtarget area is specified to the work;

FIG. 26 shows a flowchart of a procedure when height inspection of thework of FIG. 16 is performed; and

FIGS. 27A and 27B show explanatory views of an example in which themeasurement target area and the search area follow a positional changeof the work.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows a configuration of an imaging unit of an inspectionapparatus (image processing apparatus) to which the invention is appliedalong with an installation example. The inspection apparatus accordingto a preferred embodiment of the invention has measurement processingfunctions used for both the three-dimensional measurement and thetwo-dimensional measurement. In the inspection apparatus, inspectionobjects W (hereinafter referred to as “work”) conveyed on an inspectionline L in a plant are sequentially imaged with an imaging unit 1, and ameasurement process or a determination process are performed accordingto various inspection purposes. The imaging unit 1 is formed byincorporating two cameras C0 and C1 into a chassis 15, and the imagingunit 1 is installed above the inspection line L. The camera C0 isinstalled while an optical axis of the camera C0 is orientated toward avertical direction (the work W is seen from the front side). The cameraC1 is installed with the optical axis inclined such that a visual fieldof the camera C1 overlaps that of the camera C0. An imaging surfacedefining each visual field range of the cameras C0 and C1 is formed in arectangular shape. The cameras C0 and C1 stand in line such that thecamera C1 is located along a crosswise direction (corresponding tox-axis direction of an image A0 of FIG. 2) of the visual field range ofthe camera C0.

FIG. 2 shows examples of the images of the work W, which are generatedby the cameras C0 and C1. The sign A0 designates an image (correspondingto a first image) from the camera C0, and the sign A1 designates animage (corresponding to a second image) from the camera C1. In thedrawings such as FIG. 2 and FIG. 13 in which the image of the work isillustrate, similarly to FIG. 1, the work in the images A0 and A1 arealso designated by the sign W. The crosswise direction (horizontaldirection) of the image A0 is set at the x-axis direction, and alongitudinal direction (vertical direction) is set at a y-axisdirection.

Because the camera C0 is installed while the optical axis is orientatedtoward the vertical direction, the image A0 shows a state in which anupper surface of the work W is seen from the front side. On the otherhand, because the camera C1 is installed while the optical axis isobliquely orientated, the work W emerges on the image A1 while the workis seen from the oblique direction. Focusing on the characteristics ofthe images, in the inspection apparatus, a measurement target positionis specified using the image A0 on the side of the camera C0 in whichthe image gas small distortion (close to a plan view of the work W), andthen a position corresponding to the measurement target position on theimage A0 is specified using the image A1 on the side of the camera C1.

FIG. 3 is a block diagram showing an entire configuration of theinspection apparatus. In addition to the imaging unit 1, the inspectionapparatus includes a main body unit 2, a monitor 3, and a console 4. Themain body unit 2 includes image input units 20 and 21 for the cameras C0and C1, a camera drive unit 22, an image memory 23, a processing unit24, a memory 25, a display control unit 26, and an output unit 27.

The camera drive unit 22 receives a detection signal from a sensor (notshown) for work detection to simultaneously drive the cameras C0 and C1.The image input units 20 and 21 includes an A/D conversion unit and animage buffer. The image input units 20 and 21 perform digital conversionto image signals generated by the cameras C0 and C1, and digital images(images A0 and A1) for measurement process are generated in the camerasC0 and C1 respectively. The images A0 and A1 are stored in image buffersof the image input units 20 and 21, and the images A0 and A1 are readand stored in the image memory 23 according to a command from theprocessing unit 24.

The processing unit 24 includes CPU and peripheral circuits thereof. Thememory 25 is a non-volatile memory such as EEPROM. Programs (a programfor controlling the apparatus operation, a program for executing eachimage processing item, an image processing sequence, and the like),parameters for three-dimensional measurement (corresponding to acoefficient of a computation formula for computing a three-dimensionalcoordinate), various data files necessary for the measurement are storedin the memory 25. The processing unit 24 performs the measurement of thework W and the determination process by executing a process to theimages A0 and A1, stored in the image memory 23, according to thelater-mentioned sequence

The display control unit 26 receives the images A0 and A1 from the imageinput units 20 and 21 to generate a display screen including the imagesA0 and A1, and the display control unit 26 display the display screen onthe monitor 3. The processing unit 24 appropriately controls the displaycontrol unit 26 to display measurement result and inspection resultalong with the images A0 and A1, and the processing unit 24 alsocontrols the display control unit 26 to display the later-mentionedsetting screen.

The output unit 27 is an output interface which outputs the results ofthe measurement process and determination process to an external devicesuch as PLC.

In the inspection apparatus of the embodiment, plural kinds ofprocessing items are prepared to various processes performed for themeasurement or inspection, and a user selects the processing items andthe executing procedure, which builds a series of sequences from theimage input to the process of outputting the executed result.

FIG. 4 shows a system configuration for setting the sequence. The systemincludes a processing item table 201, a sequence retention unit 202, aprogram storage unit 203, a specification operation receiving unit 204,a sequence building unit 205, a sequence executing unit 206, and aprocessed-result output unit 207. The processing item table 201, thesequence retention unit 202, and the program storage unit 203 are storedin the form of a file in the memory 25, and other configurations are afunction which is set in the processing unit 24 by the program forcontrolling the apparatus operation stored in the memory 25.

In each purpose of the process, plural processing items are registeredin the processing item table 201. FIG. 5 shows an example of theprocessing item table. The specific processing items are set in eachkind of the processes such as “image input concern,” “positionalcorrection concern,” and “general measurement concern.”

In the processing item table, the processing items belonging to “imageinput concern” correspond to the purpose of obtaining the process targetimage. The processing items belonging to “positional correction concern”correspond to the purpose that the position of the measurement targetregion is kept constant in the image by correcting position shift of themeasurement target region on the work in the image.

The processing items belonging to “general measurement concern”corresponds to the purpose that the measurement is performed to themeasurement target region, and “general measurement concern” is dividedinto two kinds of the processes of “positioning” and “measurement.”“Positioning” is a process of specifying the measurement target positionon the image A0. The position specified by performing the processingitem belonging to “positioning” can be used for the three-dimensionalmeasurement, and sometimes the processing item belonging to“positioning” is performed in order to perform the two-dimensionalposition measurement of itself on the image A0. The measuredtwo-dimensional position can be used for the computation of a dimensionbetween two points on the image A0 and the like.

“Measurement” is a process of finding the position on the image A1corresponding to the measurement target position specified on the imageA0 to compute the three-dimensional coordinate of the measurement targetposition in the case where the three-dimensional measurement isperformed. The two-dimensional measurement processes such as a processof determining an area of the measurement target region for the image A0and a process of determining average density are also set as theprocessing item belonging to “measurement.”

Returning to FIG. 4, in each processing item registered in theprocessing item table 201, the program for executing the process of eachitem is stored in the program storage unit 203. The specificationoperation receiving unit 204 reads various processing items from theprocessing item table 201 to display the processing items on the monitor3, and the specification operation receiving unit 204 receives thespecification operation by the console 4. In the specificationoperation, the processing items to be used are selected, and theexecuting procedure of the selected processing items is specified.

The specification operation receiving unit 204 transfers receivedspecification contents to the sequence building unit 205, and thesequence building unit 205 builds the sequence according to thespecification. The sequence built by the sequence building unit 205 isregistered in the sequence retention unit 202. Specifically, thesequence has a data structure in which pieces of code informationcorresponding to the specified processing items are arranged in thespecified order. The processing item table 201, the sequence retentionunit 202, the specification operation receiving unit 204, and thesequence building unit 205 corresponds to the sequence setting means,and the sequence executing unit 206 corresponds to the sequenceexecuting means.

After the sequence executing unit 206 reads the sequence stored in thesequence building unit 205, the sequence executing unit 206 sequentiallyreads the programs corresponding to the processing items constitutingthe sequence from the program storage unit 203 and sequentially executesthe programs. The processed-result output unit 207 outputs the processresult finally obtained by executing the sequence.

For the plural frequently utilized measurement purposes, each processingitem sequence indicating the flow from the image input to thetwo-dimensional measurement or the three-dimensional measurement ispreviously registered in the sequence retention unit 202. Hereinafterthe processing item sequence for the frequently utilized measurementpurpose is referred to as “basic sequence.”

The specification operation receiving unit 204 can call and displayvarious sequences (including the basic sequences) registered in thesequence retention unit 202 and displays the sequences, and thespecification operation receiving unit 204 can receives the selectionoperation. When one sequence is selected to execute the sequence, theprocess is transferred from the specification operation receiving unit204 to the sequence executing unit 206, and the selected sequence isexecuted.

after the selection of the sequence, the specification operationreceiving unit 204 can accept an operation of adding the processingitem, an operation of partially changing the processing items, and thelike. In this case, the selection result of the sequence and subsequentoperation contents are transferred to the sequence building unit 205,and the process of editing the selected sequence is performed. For thebasic sequence, the addition, change, deletion, and the like of theprocessing item can freely be performed. The edited sequence isregistered by replacing the preceding sequence, or edited sequence canbe registered as the new sequence.

FIG. 6 shows a menu display example of the sequence registered in thesequence retention unit 202. In FIG. 6, each sequence in the menu iscalled scene, and an individual “scene name” (“edge position” and thelike) is imparted to each sequence. In the display example of FIG. 6,the basic sequence of the three-dimensional measurement is registered incolumns 0 to 3 while columns 4 to 7 are unregistered, and initial namessuch as “scene 4” are displayed in the columns 4 to 7. When the sequenceexcept for the basic sequence is registered, the new name is displayedfrom the column 4 in the screen.

The basic sequence of the three-dimensional measurement shown in FIG. 6will briefly be described. “Edge position” is applied in measuring thethree-dimensional coordinate at an edge point of the measurement targetregion. In “edge position,” the position of the edge point which is ofthe measurement target is specified on each of the images A0 and A1 tocompute the three-dimensional coordinate of the edge point. “Pattern” isapplied in measuring the region including a predetermined pattern suchas characters and drawing pattern. In “pattern,” a representativeposition of an area corresponding to the pattern of a previouslyregistered model (hereinafter simply referred to as “model”) isspecified from the Images A0 and A1, and the three-dimensionalcoordinate of the representative position is computed.

“Height measurement” is applied in the case where the pattern of themeasurement target region is not constant (patterns are different fromone another). In “height measurement,” the measurement target area andthe representative position are specified in the image A0 based on thepreviously specified position information, the pattern is obtained inthe measurement target area, the area corresponding to the patternobtained from the image A0 is searched to specify the representativeposition on the image A1, and the three-dimensional coordinate of therepresentative position is computed from the representative positions ofthe images A0 and A1. The above processing item is called “heightmeasurement” because height information (Z coordinate) is frequentlyobtained while the camera C0 is arranged to see the work from the frontside (to vertically see the work).

Although “multi-point height measurement” is basically similar to“height measurement,” “multi-point height measurement” is used tomeasure the heights of plural points in the specified area.

When any one of sequences is selected from the display menu, the monitorscreen is changed to the display indicating the contents of the selectedsequence.

FIG. 7A shows a display screen when “edge position” of FIG. 6 isselected. The processing items to be executed are displayed along withthe numericals (0,1, 2, 3) which indicate the executing orders. FIG. 7Bshows a flowchart for which the displayed sequence of “edge position” isreplaced. IN FIG. 7B, Steps 0 to 3 correspond to the numericalsindicating the executing procedure respectively. The process flow of“edge position” will be described below with reference to the flowchartof FIG. 7B.

In Step 0 (stereo camera image input), the cameras C0 and C1 are drivento generate the images A0 and A1, and the image A0 is stored in theimage memory 23. The image A1 is also held in the image buffer of theimage input unit 11.

In Step 1 (shading edge position), x and y coordinates of the edgeposition are specified by performing binarization and a projectionprocess to the measurement target area in the image A0. In Step 2(camera change), the image A1 is read from the image buffer of the imageinput unit 11 corresponding to the camera C1, and the image memory 23 isupdated by the image A1.

In Step 3 (stereo edge position), process target is set at the image A1,and the position corresponding to the edge position specified in Step 1is specified based on the camera coordinate system correlation betweenthe cameras C0 and C1. The three-dimensional coordinate is computedusing the position specified on the image A0 and the position specifiedon the image A1.

FIG. 8A shows a display example of the monitor 3 when “pattern” isselected in the menu of FIG. 6, and FIG. 8B shows a flowchart for which“pattern” displayed on the display screen is replaced. The process flowof “pattern” will be described below with reference to the flowchart ofFIG. 8B.

In Step 0 (stereo camera image input), similarly to Step 0 of the “edgeposition,” the cameras C0 and C1 are driven to generate the images A0and A1, and the image A0 is stored in the image memory 23.

In Step 1 (high-accuracy ECM (Edge Code Model) search), the processtarget is set at the image A0 to specify the representative position(for example, a center position of the area) of the area (matching forthe model image) having a high degree of correspondence to thepreviously registered model image. In the process in Step 1, the imageA0 is differentiated to extract the point where differentiation of thedensity is a constant value or more, a density gradient direction(expressed as angle data EC (Edge Code)) is computed at the point, and adistribution pattern of the angle data EC is checked against adistribution pattern of the angle data EC in the model image. JapanesePatent Application Laid-Open No. 2002-230549 discloses the detailedprocess method.

In Step 2 (camera change), similarly to Step 2 of “edge position,” theimage memory 23 is updated by the image A1 on the side of the camera C1.In Step 3(stereo high-accuracy ECM search), similarly to the image A0,the process target is set at the image A1 to specify the representativeposition (for example, the center position of the area) of the areahaving a high degree of correspondence to the previously registeredmodel image. Then, the three-dimentional coordinate is computed usingthe position specified on the image A0 and the position specified on theimage A1.

Similarly, for the basic sequence of the three-dimensional measurement,the process target is set at the image A0 on the side of the camera C0to specify the position of the point or the representative position ofthe area which is of the target of the three-dimensional measurement.Then, the process target is changed to the image A1 to determine theposition of the point or the representative position of the area whichcorresponds to the position specified on the side of the image A0, andthe three-dimensional coordinate or the Z coordinate is computed.

Referring to the processing item table 201 shown in FIG. 5, Step 0 andStep 2 of FIGS. 7 and 8 correspond to the processing items of the imageinput concern. Step 1 corresponds to the processing items of thepositioning concern, and Step 3 corresponds to the processing items ofthe measurement concern. In order to perform the three-dimensionalmeasurement with the configuration of the inspection apparatus theembodiment, it is necessary to select the processing items correspondingto the processes of Steps 0 to 3 (however, Step 2 is not required whenboth the images A0 and A1 can be stored in the image memory).

In the basic sequence of the three-dimensional measurement, theprocessing items corresponding to the processes of Steps 0 to 3 isalready selected, so that a user can perform the measurement processaccording to the purpose by selecting the conditions that specify theposition of the inspection target region of the work W or the basicsequence suitable for the measurement purpose.

It is also possible that both plural processing items of the positioningconcern and the plural processing items of the measurement concern areselected in one sequence. For example “edge position” and “high-accuracyECM search” can be selected as the positioning concern and “stereo edgeposition” and “stereo high-accuracy ECM search” can be selected as themeasurement concern. In this case, the position specified by the processof “edge position” is imparted to the process of “stereo edge position,”and the specification of the corresponding position and the computationof the three-dimensional coordinate are performed in the process of“stereo edge position.” The position specified by the process of“high-accuracy ECM search” is imparted to the process of “stereohigh-accuracy ECM search,” and the specification of the correspondingposition and the computation of the three-dimensional coordinate areperformed in the process of “stereo high-accuracy ECM search.”

In one sequence, it is also possible to set the same processes pluraltime. For example, the same processes of “high-accuracy ECM search” areset plural times, and the same number of processes of “stereohigh-accuracy ECM search” as “high-accuracy ECM search” can be set. Inthis case, the three-dimensional coordinate is computed in each pair ofthe process of “high-accuracy ECM search” (positioning) and the processof “stereo high-accuracy ECM search” (measurement).

It is necessary to specify the performance of the three-dimensionalmeasurement with which pair of the positioning process (first on-imageposition specification process) and the measurement process (secondon-image position specification process). Specifically, a numericalindicating what number of the positioning process corresponding to theprocess in the sequence is included in the setting items for eachmeasurement process.

Alternatively, in the case where the images A0 and A1 are simultaneouslystored in the image memory 23, because Step of “camera change” is notrequired, the positioning process and the three-dimensional measurementprocess may be treated in pairs, when the positioning process and thethree-dimensional measurement process are sequentially continuously setin the sequence.

Although only the processing items necessary for the three-dimensionalmeasurement are set in the basic sequences of FIGS. 7 and 8, otherprocessing items can be added if required. FIG. 9 shows an example inwhich the processing item of the positional correction concern is addedto the basic sequence of “edge position” of FIG. 7. The user operationprocedure in the case of the addition of the processing item will bedescribed below with reference to flow of FIG. 9.

A user places a cursor 31 on the processing item executed immediatelyafter the newly added process (FIG. 9A), and the user performs the editoperation (in this case, the user simultaneously operates a shift keyand an enter key). When the edit operation is performed, as shown inFIG. 9B, a selection box 32 is set in the display screen, and a word(change, insert, and the like) indicating an edit method is displayed inthe selection box 32.

When the user selects “insert” in the selection box 32, as shown in FIG.9C, the selection box 32 is changed to display the setting item in thecolumn of type of the processing item table 201. When the user selectsthe predetermined item (“positional correction concern” in the exampleof FIG. 9C), as shown in FIG. 9D, a new selection box 33 is set todisplay the processing items included in the selected type. When theuser selects the desired item (“model position correction” in theexample of FIG. 9D), as shown in FIG. 9E, the selected processing itemis inserted into the position specified by the cursor 31 in the basicsequence.

In the selection box 32 of FIG. 9B, when the user selects “change,” thecurrently selected processing item (shading edge position) can bereplaced for another processing item. The currently selected processingitem can be deleted by selecting “delete.” The currently selectedprocessing item can be stored to set the same item in another Step byselecting “copy.” The copy function can be utilized in the case wherethe plural measurement target regions (IC leads) exist to necessary tospecify the measurement position in each measurement target region likethe work W shown in FIGS. 1 and 2.

The edition of the basic sequence is described in the above embodiment.However, in the case where the necessary processing item is directlyread from the processing item table 201 to perform complete manualsetting without using the basic sequence, the same selection boxes 32and 33 as those of FIG. 9 are displayed, so that the user can select thenecessary processing item without question.

Not only the processing item for the three-dimensional measurementprocess but also the processing item for the two-dimensional measurementprocess are registered in the processing item table 201. For example, apattern matching process is registered as the processing item forinspecting a print state of the characters printed on the work W, or aprocess of computing a density average value or density deviation isregistered as the processing item for detecting a fault such as a flawand a chip. These processing items are incorporated into the sequencealong with the processing items of the three-dimensional measurement,which allows the measurement processes of the two-dimensional andthree-dimensional to be efficiently performed.

FIG. 10 shows an example in which a process of performing thetwo-dimensional measurement is added to the basic sequence of “edgeposition” of FIG. 7. In the example of FIG. 10, “density average anddeviation” is set as the processing item concerning the two-dimensionalmeasurement after “stereo camera image input” of Step 0, and theprocessing items similar to the basic sequence are set subsequent to“density average and deviation.”

Referring to the edited sequence, the image A0 stored in the imagememory 23 is set at the process target to perform the process ofcomputing the density average and deviation, the target position of thethree-dimensional measurement is specified using the same image A0, andthen the transition to the process for the image A1 is made. Therefore,the same images as the three-dimensional measurement can be used for thetwo-dimensional measurement. The number of updates for the image memory23 can be limited to once like the basic sequence, so that the delay ofthe process can be prevented.

Then, the above embodiment will be described in more detail. In thefollowing description, the image A0 taken by the camera C0 is referredto as “front image A0” and the image A1 taken by the camera C1 isreferred to as “oblique image A0.”

FIG. 11 is a block diagram showing an entire configuration of theinspection apparatus, and FIG. 11 shows contents of the inspectionapparatus of FIG. 3 in more detail. The description of the samecomponent as that shown in FIG. 3 will be omitted. An intra-apparatuscomputer 200 is provided in the inspection apparatus of FIG. 11.

The intra-apparatus computer 200 performs the measurement process usingeach image of the cameras C0 and C1, and the intra-apparatus computer200 determines whether the work W is acceptable of defective from theresult of the measurement process. In addition to the image memory 23 inwhich the images A0 and A1 are stored, the intra-apparatus computer 200includes an image processing unit 41, a measurement processing unit 42,a determination unit 43, the display control unit 26, a parametercomputation unit 44, and a parameter storage unit 45. The units exceptfor the image memory 23 and the parameter storage unit 45 are a functionwhich is set in the intra-apparatus computer 200 by a dedicated program.The image memory 23 and the parameter storage unit 45 are set in thememory (such as RAM and EEPROM) of the intra-apparatus computer 200.

In the above configuration, the image processing unit 41, themeasurement processing unit 42, the determination unit 43, the parametercomputation unit 44, and the parameter storage unit 45 correspond to theprocessing unit 24 of FIG. 3. A memory (not shown, corresponding to thememory 25 of FIG. 3) for registering information necessary for theinspection (such as setting conditions of the inspection area and modelimage) is also provided in the intra-apparatus computer 200. The processof registering the information in the registration memory or the processperformed by each unit of the intra-apparatus computer 200 canappropriately be set or changed according to the operation of theconsole 4.

The image processing unit 41 extracts a constituting point of the work Wby the binarization, the edge extraction, the pattern matching, and thelike. The measurement processing unit 42 performs the process ofmeasuring the position, the size, and the like with respect to theinspection target region extracted by the image processing unit 41. Theimage processing unit 41 and the measurement processing unit 42 are setso as to select and perform the two-dimensional process and thethree-dimensional process.

The determination unit 43 compares the measurement result of themeasurement processing unit 42 to a predetermined threshold to determinewhether the work W is acceptable or defective. The measurement resultand the determination result are outputted to the output unit 27 and thedisplay control unit 26. The display control unit 26 controls thedisplay operation of the monitor 3. The display control unit 26 cancause the monitor to simultaneously display the front image A0 and theoblique image A1, generated by the image input units 20 and 21, in onescreen. The display control unit 26 can also receive the process resultsof the image processing unit 41, measurement processing unit 42, anddetermination unit 43 to cause the monitor to appropriately display theprocess results along with the image.

Various coefficients included in the computation formula for thethree-dimensional measurement are stored in the parameter storage unit45. These coefficients (hereinafter the coefficients are referred to as“parameter”) are varied according to correlation (a distance betweenorigins of coordinates, a rotational shift amount of spatial coordinatesystem, and the like) between a stereo coordinate system formed by thecameras C0 and C1 and the spatial coordinate system indicating theposition in the actual space. The parameters are computed by the imageprocessing unit 41 and the parameter computation unit 44 in advance ofthe inspection, and the parameters are stored in the parameter storageunit 45. A calibration work having plural feature points is used in theprocess of computing the parameter. The parameter constituting ahomography matrix of the later-mentioned computation formula (1) is alsoregistered in the parameter storage unit 45.

In the inspection apparatus of the embodiment, the inspection algorithm(sequence) can be built by presenting the plural kinds of the inspectionmenus (processing item or sequence of the registered processing item) tothe user to receive the selection operation. The inspection by thetwo-dimensional measurement process and the inspection by thethree-dimensional measurement process can be selected and performedaccording to the inspection target region. In the inspection performedby the two-dimensional measurement process, the front image A0 from thecamera C0 is set at the process target. Then, the pattern matchingprocess, the binarization process, the edge extraction process, and thelike are performed to extract the whole work or the inspection targetregion of the work.

In the embodiment, the speed of the three-dimensional measurementprocess is increased by effectively utilizing the front image A0 fromthe camera C0 for the inspection by the three-dimensional measurementprocess. The speedup of the three-dimensional measurement process willbe described later.

Taking the IC inspection with the inspection apparatus as an example,the processes concerning the inspection will be described in detail.FIG. 12 shows the inspection procedure when the work is IC. Theprocedure is started by receiving a detection signal from a workdetection sensor. In ST1 (hereinafter Step is abbreviated as ST), thecamera drive unit 12 simultaneously drives the cameras C0 and C1 togenerate the front image A0 and the oblique image A1.

The inspection of the characters printed on a package portion of IC isperformed in ST2. In the inspection, two-dimensional image processing isperformed only using the front image A. For example, the characterprinted area is extracted by the pattern matching process, and it isdetermined whether the character printed state is acceptable ofdefective according to a degree of correlation during the matching orthe matching position.

In ST3, the leads on both sides of IC are set at the inspection target.In the inspection, the three-dimensional coordinate of a front endportion in each lead is determined by the three-dimensional measurementprocess using both the front image A0 and oblique image A1, and it isdetermined whether anomaly such as floating and bending is generated inthe front end portion of each lead based on the three-dimensionalcoordinate.

When the inspections of ST2 and ST3 are ended, the inspection resultsare outputted to the external device and the monitor 3 in ST4. When thenext IC is detected by the work detection sensor, the flow returns toST1, and the same procedure is performed.

Thus, the inspection performed by the two-dimensional measurement andthe inspection performed by the three-dimensional measurement cancontinuously be performed by imaging the work W once with the twocameras C0 and C1. The front image A0 is used in the two-dimensionalmeasurement process, measurement process can accurately be performedwith the image in which the characters have no distortion.

In performing the three-dimensional measurement process, the point ofthe measurement target is specified between the front image A0 and theoblique image A1, and the computation is performed by applying thethree-dimensional coordinate to the computation formula based on atriangular principle.

FIG. 13 shows setting examples of the detection area in the front imageA0 and the detection area in the oblique image A1. Similarly to FIG. 2,the longitudinal direction (direction along an array of the leads in thefront image A0) of the image is set at the y direction, and thecrosswise direction (direction along the length of lead in the frontimage A0) is set at the x direction. In the front image A0, a detectionarea 7 is set in each lead 6, and one edge point corresponding to afront end of the lead is specified in each detection area 7.

In this case, because the cameras C0 and C1 are arranged in the xdirection, a parallax is mainly generated in the x direction. Therefore,a histogram is produced by binarizing the image in the detection area 7to project the obtained binary image along the y direction. In thehistogram, the x direction is set at a horizontal axis, and the numberof “bright” pixels or the number of “dark” pixels is set at a verticalaxis. An x coordinate where histogram is rapidly changed is set at an xcoordinate of the front end of the lead 6. On the other hand, a ycoordinate of a midpoint in the y direction of the detection area 7 isset at a y coordinate of the front end of the lead 6. In this case, theimage in the detection area 7 is binarized. Alternatively, in theshading image in the detection area 7, density of each pixel isintegrated in the y direction, and the x coordinate may be determined atthe point where the obtained integral density distribution is rapidlychanged in the x direction (for example, the point where the integraldensity distribution intersect a threshold). Thus, in the detection area7, the particular one direction becomes the edge detection target. InFIG. 13, the x direction becomes the edge detection direction, and theedge detection target is specified for the detection area 7 after thedetection area 7 is set in the front image A0. Alternatively, thedetection area 7 including the unique edge detection direction may beset in the front image A0, or the detection area 7 is set in the frontimage A0 after the edge detection direction of the detection area 7 isspecified.

In the oblique image A1, a detection area 8 is set in each lead 6. Thedetection area 8 is set by using the coordinate of the edge pointspecified in each detection area 7 of the front image A0, a height range(height range of the inspection target region) specified by a user, andthe like based on the later-mentioned computation formula (1) whichconverts one point on one image into one point on the other image. Theheight range is a three-dimensional measurement target range along theoptical axis of the camera C0.

Although only the area setting for the leads on the right sides of thework W is shown in FIG. 13, the same setting is performed for the leadson the left side (the same holds true for the following drawings).

FIG. 14 shows a procedure of a teaching process for the IC leadinspection. The procedure of FIG. 14 is performed before the ICinspection of FIG. 4 is started. In ST11, the length of lead 6, a pitchbetween the leads 6, and the like are inputted for the work W (IC inthis example) of the inspection target. The input data is registered ina working memory, and the data is used in ST15.

In ST12, the acceptable work is placed at the imaging target position,and the acceptable work is taken by the cameras C0 and C1. In theteaching process, it is necessary to generate only the front image A0from the camera C0. However, in the embodiment, the cameras C0 and C1are simultaneously driven even in the teaching process, and the twogenerated images are display on the monitor 3.

In ST13, the positioning area is specified in the front image A1. FIG.15 shows a display example of the front image A1 during thespecification operation. In FIG. 15, the numeral 9 designatespositioning area. The positioning area 9 is used to extract the lead(the front-end lead 6 a in FIG. 15, hereinafter referred to as“front-end lead 6 a”) located at the end of the array of the leads 6. InFIG. 15, the square area 9 is set so as to include only the front-endlead 6 a. In the positioning area 9, even if the position of the work Wis shifted within an envisaged extent, the size of the positioning area9 is adjusted such that the front-end lead 6 a can be imaged in thepositioning area 9. The positioning area 9 is also set such that thefront-end lead 6 a is imaged in a lower half range of the positioningarea 9. Therefore, because the lead is not imaged in the upper halfrange of the positioning area 9, it can be confirmed that the leadimaged in the lower half range of the positioning area 9 is thefront-end lead 6 a.

Returning to FIG. 14, when the positioning area 9 is specified, thefront-end lead 6 a is extracted from the positioning area 9 in ST14. Inthe extraction process, for example, the y coordinate of the front-endlead 6 a is determined by the method, in which the image in thepositioning area 9 is binarized and the binarized image is projectedalong the x-axis direction. Alternatively, a borderline of the lead maybe extracted to determine the center line of the lead by extracting anedge or a density gradient direction in the positioning area 9.

In ST15, the detection area 7 is set in each lead 6 based on the ycoordinate of the front-end lead 6 a and the data inputted in ST11. Inthe embodiment, the length of the lead 6 and the pitch between the leads6 on the image are computed with the data inputted in ST11, the numberof pixels of camera C0, magnification, and the like, and the size ofeach detection area 7 and an interval between areas are determined basedon the computed values. The detection area 7 having the size determinedin each interval is set at each of the leads 6 including the front-endlead 6 a based on the position of the front-end lead 6 a. This isbecause the front image A0 in which characteristics (such as equallength of each lead and equal pitch between leads) in the inspectiontarget region of the work W are directly reflected is used. Accordingly,when the front-end lead 6 a can be extracted, the detection area 7 canbe set in all the leads 6 even if another lead 6 is not extracted, sothat the process efficiency can largely be improved.

In ST16, the setting conditions (the position and size of the area) ofthe positioning area 9 specified in ST13 and the setting conditions ofthe detection area 7 specified in ST15 are registered in a registrymemory. In ST17, the image in the positioning area 9 is registered asthe model in the registry memory. Then, the teaching process is ended.It is desirable that image showing the setting result of the detectionarea 7 is displayed on the monitor 3 to perform the registry accordingto confirmation operation of a user prior to ST16. At this point, theposition and size of the detection area 7 may finely be adjusted

FIG. 16 shows a detailed procedure for the IC lead inspection (ST3 inFIG. 12). The processes from ST21 to ST24 in the procedure of FIG. 16are performed to the front image A0. In ST21, the positioning area 9 isset in the front image A0 based on the setting conditions registered inthe teaching process. In ST22, the image in the positioning area 9 iscollated with the model registered in ST17 of the teaching process, ashift amount is extracted with respect to the model (for example, apattern matching technique can be applied to the process). ST21 and ST22correspond to the processing item of “model position correction” in theprocessing item table 201.

In ST23, the setting conditions of the detection area registered in theteaching is adjusted based on the shift amount extracted in ST22, andthe detection area 7 of each lead is set according to thepost-adjustment setting conditions. In the front image A0, because it isnot necessary to consider the distortion of the work W, the shift amountof positioning area 9 can directly be applied to each detection area 7,and the detection area 7 can be set for each lead 6 while the samepositional relationship as the teaching process is held.

FIG. 17 shows an example of the front image A0 during the inspection.Because the work W of FIG. 17 is shifted rightward compared with theimage A0 of FIG. 7 in the teaching, the front end of the lead 6 isprotruded from the positioning area 9. However, the above adjustmentprocess is performed for the detection area 7, so that the detectionarea 7 is set in each lead on the same conditions as FIG. 4.

When the detection area 7 is set in each lead, the x and y coordinatesof the front end of the lead are computed in each detection area 7 inST24. ST23 and ST24 correspond to the processing item of “shading edgeposition” in the processing item table 201. The processing item isrepeatedly set with the same number of repetitions as the number ofleads. The processing item of “camera change” is performed (not shown)after the processing item of “shading edge position.”

In ST25, the detection area 8 for the front end portion of each lead isset on the oblique image A1. In ST26, the same process as ST24 isperformed to compute the x and y coordinates of the front end of thelead in the set detection area 8.

In ST27, the three-dimensional coordinate of each front end is computedusing the coordinates computed in ST24 and ST26. In ST28, the computedthree-dimensional coordinate is compared to a previously registeredreference value to determine whether the front end portion of each ledis acceptable or defective. For example, when the floating exists in thefront end portion, the z coordinate expressing the height exceeds thereference value, and it is determined that the front end is defective.ST25 to ST27 correspond to the processing item of “stereo edgeposition.” The processing item is repeatedly set with the same number ofrepetitions as the number of leads.

Then, the setting of the detection area 8 in ST25 will be described indetail. FIG. 18 shows state in which a point P on a plane D located atan arbitrary height position in a space is imaged on point p₀ and p₁ onimaging surfaces F0 and F1 of the cameras C0 and C1 respectively. InFIG. 18, X, Y, and Z are a coordinate axis expressing athree-dimensional space, and a plane D is parallel to an XY plane. Atwo-dimensional coordinate system having x₀and y₀ axes is set in theimaging surface F0 and a two-dimensional coordinate system having x₁ andy₁ axes is set in the imaging surface F1. In FIG. 18, the position ofthe point P can arbitrarily set on the plane D.

Assuming that the coordinate of the imaging position (point p₀) in theimaging surface F0 of the point P is set at (x_(cam0),y_(cam0)) whilethe coordinate of the imaging position (point p₁) in the imaging surfaceF1 of the point P is set at (x_(cam1),y_(cam1)), the relationshipbetween the points p₀ and p₁ is obtained by the following formula (1).$\begin{matrix}\left\lbrack {{Formula}\quad 1} \right\rbrack & \quad \\{{\lambda\begin{bmatrix}x_{{cam}\quad 1} \\y_{{cam}\quad 1} \\1\end{bmatrix}} = {{Hz}\begin{bmatrix}x_{{cam}\quad 0} \\y_{{cam}\quad 0} \\1\end{bmatrix}}} & (1)\end{matrix}$

In the formula (1), Hz is a 3×3 homographic matrix expressing therelationship between the imaging position on the imaging surface F0 andthe imaging position of the imaging surface F1 with respect to the planeD having the height Z, and λ is a constant. The matrix H_(z) canpreviously be determined by calibration with the already know coordinateon the plane D (for detail of the calibration, see N. Miichi, T. Wada, TMatsuyama “Study on calibration of the projector camera system” theInternetURL:http://vision.kuee.kyoto-u.ac.jp/Research/Thesis/Thesis_PDF/Miichi_(—)2002_P_(—)147.pdf).

Assuming that the front end of the lead extracted in each detection area7 of the front image A0 is the point p₀ to substitute the coordinate ofthe point p₀ for (x_(cam0,y) _(cam0)) of the formula (1), it can bethought that the computed (x_(cam1),y_(cam1)) corresponds to theposition of the front end of the lead in the oblique image A1. However,when the height of the front end of the lead is fluctuated, the height Zof the plane D is also fluctuated, and the homographic matrix H_(z) ischanged with the fluctuation in height Z of the plane D. Accordingly,(x_(cam1),y_(cam1)) is also changed.

In ST25, on the basis of the above principle, the coordinates of twopoints e and f shown in FIG. 19 are obtained as (x_(cam1),y_(cam1)) bycomputing the formula (1) with the homographic matrix H_(z) according toeach height Z, both in the case the upper limit of envisaged heightrange (the three-dimensional measurement target range along the opticalaxis of the camera C0) is set at the height X of the plane D and in thecase where the lower limit is set at the height Z. As shown in FIG. 19,in the oblique image A1, a line segment gh and a line segment g'h' areformed, and a rectangular area ghh'g' is set at the detection area 8.The line segment gh and the line segment g'h' are moved by a half-valuewidth k of the detection area 7 on the side of the front image A0 inparallel with a line segment ef on both sides in the directionperpendicular to the line segment ef.

FIG. 20 shows size comparison of the detection area 8 between the casewhere the possible height of the lead 6 ranges from 0 to 5 mm withrespect to the oblique image A1 similar to FIG. 13 and the case wherethe height ranges from −15 to 15 mm. As can be seen from FIG. 20, thedetection area 8 is decreased as the fluctuation width of the heightrange is decreased. Although the detection areas 8 are shown in parallelfor the purpose of simplification in FIG. 20, actually the detectionareas 8 are not in parallel with one another such that the intervalbetween the centerlines (line segment ef) is widened rightward, becausethe distortion is generated in the oblique image A1 by a perspectiveeffect such that the rectangular physical object is imaged in atrapezoid.

In the above embodiment, because the detection area 7 corresponding toeach lead is set in order to specify the front-end position of the leadin the reference image A0, it is necessary to set the processing itemsto the number of leads. Alternatively, the processing item, in which onelong detection area is set in the y-axis direction so as to include thefront end of each lead and the front end position of each lead isindividually determined in the detection area, may be provided.

The inspection target of the key height of a work, in which push-buttoncharacter keys are arranged, will be described below. Prior to theinspection, as shown in FIG. 21, an area 70 including the characterdrawn in a key 60 is specified in each key 60 using the front image A0which is obtained by taking the acceptable work W, and the image in thearea 70 is registered as the model.

FIG. 22 shows an inspection procedure. In ST31, the cameras C0 and C1are simultaneously driven to generate the images. ST31 corresponds tothe processing item of “stereo camera image input” in the processingitem table 201. In ST32, the pattern matching process is performed tothe front image A0 using the model registered before the inspection, anarea which corresponds best to the model is specified, and the area isset at the measurement target area. Actually the process is performed ineach model corresponding to each key 60. However, for the purpose ofsimplification, description is limited to only one key.

When the measurement target area is specified, the coordinate of therepresentative point (for example, the center point of the area) in thearea is specified in ST33. The plural representative points (forexample, points corresponding to plural feature points on the previouslydetermined model) can also be specified. ST32 and ST33 correspond to theprocessing item of “high-accuracy ECM search” in the processing itemtable 201. After the processing item is performed, the processing itemof “camera change” (not shown) is performed, and the flow goes to ST34.

In ST34, the search area is set on the oblique image A1 based on thecoordinate of the representative point. Similarly to the case where thedetection area 8 is set in the lead inspection, the homographic matrixH_(z) is while the upper limit and lower limit of the previouslyspecified height range are set at the height Z, the range whererepresentative point exists possibly on the image A1 is determined byperforming twice computations with the coordinate of the representativepoint and the upper limit and lower limit of the height range, and thearea where the size of the model is added to the range is set at thesearch area.

In ST35, in the search area, the pattern matching process is performedwith the model to specify the measurement target area and the positionof the representative point in therein. In ST36, the three-dimensionalcoordinate is computed using the coordinates of the representativepoints in the measurement target areas of the front image A0 and obliqueimage A1. In ST37, it is determined whether or not the key height isproper by comparing the Z coordinate in the computed three-dimensionalcoordinate to a predetermined threshold. In ST38, the determinationresult is outputted to end the process. ST35 to ST38 correspond to theprocessing item of “stereo high-accuracy ECM search.”

When the point corresponding to the feature point determined in themodel is specified as the representative point on the reference imageA0, similarly the corresponding point can be specified on the model inST36. Alternatively, in St35, the model is converted into the shapewhich should be taken by the oblique camera C1 using the homographicmatrix H_(z) corresponding to a predetermined height (for example,height which becomes standard when the work is normal) in the specifiedheight range, and the measurement target area may be specified using thepost-conversion model.

FIG. 23 shows a measurement target area 71 specified with respect to thekey 60 on the front image A0, a search area 80 on the side of theoblique image A1 set based on the position and size of the measurementtarget area 71, and a measurement target area 81 specified in the searcharea 80 through the above inspection.

In the procedure shown in FIG. 22, only the inspection is performed bythe three-dimensional measurement process. However, the inspection ofthe character print state of each key and the like can also be performedby the two-dimensional measurement process with the front image A0.

In the next embodiment, for the work having a circular display area inthe central portion, it is inspected whether or not the height in thedisplay area is proper. FIG. 24 shows the images A0 and A1 of the workW, which are generated by the cameras C0 and C1. In FIG. 24, the sign Sdesignates the display area of the inspection target. Similarly to theprior embodiment, the front image of the work W emerges in the frontimage A0, so that a borderline 72 of a display area S is formed in thecircular shape. On the other hand, because the distortion is generatedin the work W of the oblique image A1, the oblique image A1 differs fromthe front image A0 in the size of the display area S and the shape ofthe borderline 72, and The distortion is also generated in the characterarrangement state in the display area S.

In the embodiment, prior to the inspection, the acceptable model of thework W is imaged, and a user is caused to specify a radius of thedisplay area S and the measurement target area on the obtained frontimage A0. At this point, in the image processing unit 22, the process ofdetermining the position of the center point of the display area S fromthe front image A0 is performed to register the relative position of themeasurement target area with respect to the center point in the registrymemory.

FIG. 25 is an enlarged view showing the display area S in the frontimage A0. In FIG. 25, the numeral 73 designates the measurement targetarea specified by the user, and the numeral 74 designates the centerpoint of the display area S. The process of extracting the circularpattern from the front image A0 is performed, and the borderline 72which corresponds best to the circle (position correction model) havingthe size specified by the user is specified from the extraction result,which determines the position of the center point 74.

FIG. 26 shows the height inspection procedure for the work W of FIG. 24.In ST41, similarly to the prior embodiment, the cameras C0 and C1 aresimultaneously driven to generate the front image A0 and the obliqueimage A1. ST41 corresponds to the processing item of “stereo cameraimage input” in the processing item table 201. In ST42, the position ofthe center point 74 of the display area S is determined from the frontimage A0 by the above process. ST42 corresponds to the processing itemof “model position correction.”

In ST43, the measurement target area 73 is set based on the previouslyregistered relative position while the coordinate of the center point 74determined in ST42 is set at a reference. In ST44, the image of themeasurement target area 73 is registered as the search model image, andthe position of the representative point (for example, the position ofthe center point in the area) in the measurement target area 73 is alsoregistered. ST44 corresponds to the processing item of “stereo areasetting.” The processing item of “camera change” (not shown in FIG. 26)is performed after the processing item of FIG. 26.

In ST45, the search area 82 (shown in FIG. 27) is set on the obliqueimage A1. In the embodiment, similarly the coordinate of therepresentative point registered in ST44 is substituted in the formula(1), and the position and size of the search area 82are determined bycomputing the formula (1) using the homographic matrix H_(z) accordingto the upper limit and lower limit of the previously specified heightrange.

In ST46, a correlation matching process is performed in the search area82 using the image registered in ST44 with respect to the measurementtarget area 73 of the front image A0. The area which is most similar tothe registered image is specified, and the area is set at themeasurement target area on the side of the oblique image A1. In ST47,the coordinate of the representative point is determined for themeasurement target area on the side of the oblique image A1, and thethree-dimensional coordinate is computed using the coordinate of therepresentative point on the side of the oblique image A1 and thecoordinate of the representative point on the side of the front imageA0. In ST48, it is determined whether or not the determined Z coordinateis proper. In ST49, the determination result is outputted to end theprocess. ST45 to ST49 correspond to the processing item of “stereoheight measurement” in the processing item table 201.

FIGS. 27A and 27B show the measurement target area 73 in the front imageA0 and the search area 82 and measurement target area 83 in the obliqueimage A1 for each set of the front image A0 and oblique image A1. In thefront image A0, the borderline 72 of the display area S is indicated bya wide line, and the determined position of the center point 74 of thedisplay area S is also shown. FIG. 27A differs from FIG. 27B in theposition of the work W. However, in both the cases, the measurementtarget area 73 is correctly set such that the target character isaccommodated in the measurement target area 73.

According to the inspection procedure shown in FIG. 26, because thesearch model image is obtained from each work W of the inspectiontarget, the three-dimensional measurement can be performed by applyingthe same sequence even if the surface patterns of the target charactersof the three-dimensional measurement are different from one another. Inthis case, even if the works W is different from one another in thesurface pattern, the position of the measurement target area is commonin any work W while the shape of the work W is set at the reference, sothat measurement target area can be set.

Alternatively, in the procedure of FIG. 26, the registered search modelimage is converted into the shape which should be imaged by the obliquecamera C1 using the homographic matrix H_(z), and the measurement targetarea 83 may be specified using the post-conversion image. The process ofinspecting the character print state in the display area S with thefront image A0 can also be incorporated in the procedure of FIG. 26.

1. An image processing apparatus which performs a process with a firstimage and a second image taken by a first camera and a second camerarespectively, the first camera and the second camera being arranged soas to take a physical object from different directions, the imageprocessing apparatus comprising: sequence setting means for setting asequence of a processing item; and sequence executing means forexecuting the set sequence, wherein the sequence setting means providesplural items of two-dimensional image processing and at least one itemof a three-dimensional measurement process as the processing item whichcan be set at a sequence element by selection of a user, the provideditems of the two-dimensional image processing include at least one itemof an on-first-image position specification process of specifying aposition on a physical object in the first image, and thethree-dimensional measurement process includes an on-second-imageposition specification process of specifying a position on a physicalobject in the second image, the position on the physical object in thesecond image corresponding to the position on the physical object in thefirst image which is specified in the on-first-image positionspecification process belonging to the same sequence as the sequence towhich the on-second-image position specification process belongs to. 2.An image processing apparatus according to claim 1, wherein thethree-dimensional measurement process further includes a process ofcomputing a three-dimensional coordinate using the position specified inthe on-first-image position specification process and the positionspecified in the on-second-image position specification process.
 3. Animage processing apparatus according to claim 1, wherein a plurality ofkinds of items of the on-first-image position specification process anda plurality of kinds of items of the three-dimensional measurementprocess are provided so as to be able to be set at the sequence elementby the selection of a user.
 4. An image processing apparatus accordingto claim 1, wherein a three-dimensional measurement basic sequence isprovided so as to be able to be utilized by the selection of a user, thethree-dimensional measurement basic sequence including at least one itemof the on-first-image position specification process and at least oneitem of the three-dimensional measurement process.
 5. An imageprocessing apparatus according to claim 1, wherein a first detectionarea is set to the first image to detect an edge position in an edgedetection direction, the edge position being determined for the firstdetection area, in at least one on-first-image position specificationprocess to which the processing item is provided, and a second detectionarea is set to the second image, a particularly direction being set atthe edge detection direction in the second detection area, theparticular direction being determined based on a positional relationshipbetween the first camera and the second camera and the edge positionspecified in the on-first-image position specification process, in theon-second-image position specification process in at least onethree-dimensional measurement process to which the processing item isprovided.
 6. An image processing apparatus according to claim 5,wherein, in the second detection area, a range along the edge detectiondirection is set based on a range along an optical axis of the firstcamera which is specified by a user as a three-dimensional measurementtarget range.
 7. An image processing apparatus according to claim 5,wherein the first camera has a rectangular visual field range whilearranged so as to take the physical object from a front side, the secondcamera is located at a position which is separated from the visual fieldof the first camera in a longitudinal direction or in a crosswisedirection, the second camera is arranged so as to take the physicalobject from an oblique direction with respect to the direction in whichthe physical object is seen from the front side, the first detectionarea is set in the first image at a position based on a user command inon-first-image position specification process, and the edge detectiondirection of the first detection area is located in a row of the firstcamera and the second camera.
 8. An image processing apparatus accordingto claim 1, wherein a representative position of an area on the firstimage having a high degree of correspondence to a model image isspecified in at least one on-first-image position specification processto which the processing item is provided, the model image beingpreviously registered before the measurement is performed, and arepresentative position of an area on the second image having a highdegree of correspondence to the model image is specified in theon-second-image position specification process in at least onethree-dimensional measurement process to which the processing item isprovided.
 9. An image processing apparatus according to claim 8,wherein, in the on-second-image position specification process, a searcharea is set on the second image based on the positional relationshipbetween the first camera and the second camera and the representativepositions specified in the on-first-image position specificationprocess, and the representative position of the area having the highdegree of correspondence to the model image is specified in the searcharea.
 10. An image processing apparatus according to claim 9, whereinthe search area is set based on the range along the optical axis of thefirst camera specified by a user as the three-dimensional measurementtarget range.
 11. An image processing apparatus according to claim 1,wherein a representative position of a measurement target area set onthe first image based on the user command is specified to obtain theimage in the measurement target area as the model image in at least oneon-first-image position specification process to which the processingitem is provided, and a representative position of an area on the secondimage having a high degree of correspondence to the model image isspecified in the on-second-image position specification process in atleast one three-dimensional measurement process to which the processingitem is provided.
 12. An image processing apparatus according to claim11, wherein, in the on-second-image position specification process, asearch area is set on the second image based on the positionalrelationship between the first camera and the second camera and therepresentative positions specified in the on-first-image positionspecification process, and the representative position of the areahaving the high degree of correspondence to the model image is specifiedin the search area.
 13. An image processing apparatus according to claim11, wherein the search area is set based on the range along the opticalaxis of the first camera specified by a user as the three-dimensionalmeasurement target range.
 14. An image processing method in which afirst image and a second image respectively taken by a first camera anda second camera are used, the first camera and the second camera beingarranged so as to take a physical object from different directions, theimage processing method comprising: a sequence setting step of setting asequence of a processing item; and a sequence executing step ofexecuting the set sequence, wherein the sequence setting step providesplural items of two-dimensional image processing and at least one itemof a three-dimensional measurement process as the processing item whichcan be set at a sequence element by selection of a user, the provideditems of the two-dimensional image processing include at least one itemof an on-first-image position specification process of specifying aposition on a physical object in the first image, and thethree-dimensional measurement process includes an on-second-imageposition specification process of specifying a position on a physicalobject in the second image, the position on the physical object in thesecond image corresponding to the position on the physical object in thefirst image which is specified in the on-first-image positionspecification process belonging to the same sequence as the sequence towhich the on-second-image position specification process belongs to. 15.An image processing method according to claim 14, wherein thethree-dimensional measurement process further includes a process ofcomputing a three-dimensional coordinate using the position specified inthe on-first-image position specification process and the positionspecified in the second on-image position specification process.
 16. Animage processing apparatus which performs a process with a first imageand a second image taken by a first camera and a second camerarespectively, the first camera having a rectangular visual field rangewhile arranged so as to take a physical object from a front side, thesecond camera being located at a position which is separated from thevisual field of the first camera in a longitudinal direction or in acrosswise direction, the second camera being arranged so as to take thephysical object from an oblique direction with respect to the directionin which the physical object is seen from the front side, the imageprocessing apparatus comprising: on-first-image position specificationmeans for specifying a position on the physical object in the firstimage; on-second-image position specification means for specifying aposition on the physical object in the second image, the position on thephysical object in the second image corresponding to the position on thephysical object in the first image specified by the on-first-imageposition specification means; and three-dimensional coordinatecomputation means for computing a three-dimensional coordinate using theposition specified by the on-first-image position specification meansand the position specified by the on-second-image position specificationmeans, wherein the on-first-image position specification means sets afirst detection area at a position in the first image based on a usercommand, the on-first-image position specification means specifies anedge position in an edge detection direction determined for the firstdetection area, and the edge detection direction of the first detectionarea is located in a row of the first camera and the second camera, andthe on-second-image position specification means sets a second detectionarea to the second image, a particular direction is set at the edgedetection direction in the second detection area, the particulardirection being determined based on a positional relationship betweenthe first camera and the second camera and the edge position specifiedin the on-first-image position specification means, and theon-second-image position specification means specifies the edge positionin the edge detection direction in the second detection area.
 17. Animage processing method in which a process is performed with a firstimage and a second image taken by a first camera and a second camerarespectively, the first camera having a rectangular visual field rangewhile arranged so as to take a physical object from a front side, thesecond camera being located at a position which is separated from thevisual field of the first camera in a longitudinal direction or in acrosswise direction, the second camera being arranged so as to take thephysical object from an oblique direction with respect to the directionin which the physical object is seen from the front side, the imageprocessing method comprising: an on-first-image position specificationstep of specifying a position on the physical object in the first image;an on-second-image position specification step of specifying a positionon the physical object in the second image, the position on the physicalobject in the second image corresponding to the position on the physicalobject in the first image specified by the on-first-image positionspecification step; and a three-dimensional coordinate computation stepof computing a three-dimensional coordinate using the position specifiedby the on-first-image position specification step and the positionspecified by the on-second-image position specification step, whereinthe on-first-image position specification step sets a first detectionarea at a position in the first image based on a user command, theon-first-image position specification step specifies an edge position inan edge detection direction determined for the first detection area, andthe edge detection direction of the first detection area is located in arow of the first camera and the second camera, and the on-second-imageposition specification step sets a second detection area to the secondimage, a particular direction is set at the edge detection direction inthe second detection area, the particular direction being determinedbased on a positional relationship between the first camera and thesecond camera and the edge position specified in the on-first-imageposition specification step, and the on-second-image positionspecification step specifies the edge position in the edge detectiondirection in the second detection area.